Directed Energy Senior Opto-Mechanical Test Engineer

Worker Type Regular Job Description Summary We are seeking a highly motivated Directed Energy Senior Opto-Mechanical Test Engineer to support Manufacturing by working with the System Engineering Test Team to help development, integration, and execution of test strategies for advanced electro-optical and mechanical systems for prototype, development, and production hardware. This role will be responsible for supporting the design and test methods, fixtures, instrumentation, and automated test solutions to verify product performance, reliability, and compliance with system requirements. The ideal candidate has strong experience with opto-mechanical assemblies, precision alignment, environmental testing, data analysis, and cross-functional collaboration across mechanical, electrical, optical, software, and systems engineering teams. Position Responsibilities Work with System Engineering Test Team to refine test plans, procedures, and requirements traceability for opto-mechanical systems and/or subsystems. Develop, document, and execute test plans and procedures for optical and opto-mechanical components. Design, build, and validate test fixtures, tooling, instrumentation, for laboratory and production test areas. Execute functional, performance, qualification, environmental, vibration, shock, thermal, and reliability testing. Perform precision optical alignment and characterization of cameras, sensors, laser systems, gimbals, and related assemblies. Integrate mechanical, optical, electrical, and software components into test configurations. Analyze test data, identify trends and anomalies, and prepare clear technical reports and presentations. Troubleshoot failures and collaborate with design engineers to identify root causes and implement corrective actions. Support design reviews, risk assessments, failure investigations, and verification and validation activities. Ensure test activities comply with applicable engineering standards, quality procedures, and safety requirements. Mentor junior engineers and technicians and contribute to the improvement of test processes and capabilities. Support prototype builds, production transition, field testing, and customer demonstrations as needed. Basic Qualifications (Required Skills & Competencies) Bachelor's degree in Mechanical Engineering, Optical Engineering, Electrical Engineering, Systems Engineering, or a related technical discipline. 5-7 years of experience in engineering test, verification, integration, or a related field. Demonstrated experience testing opto-mechanical systems or precision electro-optical assemblies. Experience with optical alignment, measurement, characterization, and troubleshooting. Experience with engineering instrumentation such as oscilloscopes, power supplies, data acquisition systems, environmental sensors, optical power meters, interferometers, collimators, or similar equipment. Experience developing test fixtures. Working knowledge of mechanical drawings, GD&T, tolerance analysis, and structural interfaces. Strong technical writing, documentation, and communication skills. Ability to work effectively in a fast-paced, multidisciplinary engineering environment. U.S. Citizenship required. Ability to obtain and maintain a U.S. security clearance, if required. Other Qualifications & Desired Competencies Experience with CAD tools and the design of fixtures, tooling, or production aids. Experience with MIL-STD-810, MIL-STD-883, RTCA DO-160, or other applicable environmental and qualification standards. Familiarity with optical metrology, MTF testing, boresight alignment, image quality analysis, radiometry, or stray-light testing. Experience with vibration, shock, thermal vacuum, ingress protection, EMI/EMC, or environmental qualification testing. Knowledge of systems engineering processes, requirements management, and verification methods. Experience supporting products from prototype development through production. Prior experience in aerospace, defense, robotics, or other regulated industries. Core Competencies Opto-mechanical test and verification Optical alignment and metrology Test fixture and instrumentation design Environmental and qualification testing Root-cause analysis and troubleshooting Requirements verification and technical documentation Cross-functional leadership and mentoring Physical Demands and Work Environment Ability to work in an office, engineering laboratory, and manufacturing environment. Ability to wear required personal protective equipment. Ability to occasionally lift, carry, or manipulate materials and equipment within applicable safety limits. Ability to stand, walk, bend, reach, and work around production equipment as required. Ability to support occasional off-shift or extended-hours production activities. Travel may be required based on business needs. Clearance Level No Clearance The salary range for this role is: $91,000 - $138,750 AeroVironment considers several factors when extending an offer, including but not limited to, the location, the role and associated responsibilities, a candidate’s work experience, education/training, and key skills. ITAR Requirement: This position requires access to information that is subject to compliance with the International Traffic Arms Regulations (“ITAR”) and/or the Export Administration Regulations (“EAR”). In order to comply with the requirements of the ITAR and/or the EAR, applicants must qualify as a U.S. person under the ITAR and the EAR, or a person to be approved for an export license by the governing agency whose technology comes under its jurisdiction. Please understand that any job offer that requires approval of an export license will be conditional on AeroVironment’s determination that it will be able to obtain an export license in a time frame consistent with AeroVironment’s business requirements. A “U.S. person” according to the ITAR definition is a U.S. citizen, U.S. lawful permanent resident (green card holder), or protected individual such as a refugee or asylee. See 22 CFR § 120.15. Some positions will require current U.S. Citizenship due to contract requirements. Benefits: AV offers an excellent benefits package including medical, dental vision, 401K with company matching, a 9/80 work schedule and a paid holiday shutdown. For more information about our company benefit offerings please visit: http://www.avinc.com/myavbenefits. We also encourage you to review our company website at http://www.avinc.com to learn more about us. Principals only need apply. NO agencies please. About AV: AV isn’t for everyone. We hire the curious, the relentless, the mission-obsessed. The best of the best. We don’t just build defense technology—we redefine what’s possible. As the premier autonomous systems company in the U.S., AV delivers breakthrough capabilities across air, land, sea, space, and cyber. From AI-powered drones and loitering munitions to integrated autonomy and space resilience, our technologies shape the future of warfare and protect those who serve. Founded by legendary innovator Dr. Paul MacCready, AV has spent over 50 years pushing the boundaries of what unmanned systems can do. Our heritage includes seven platforms in the Smithsonian—but we’re not building history, we’re building what’s next. If you're ready to build technology that matters—with speed, scale, and purpose—there’s no better place to do it than AV. We are proud to be an EEO/AA Equal Opportunity Employer, including disability/veterans. AeroVironment, Inc. is an Equal Employment Opportunity (EEO) employer and welcomes all qualified applicants. Qualified applicants will receive fair and impartial consideration without regard to race, sex, color, religion, national origin, age, disability, protected veteran status, genetic data, sexual orientation, gender identity or other legally protected status. ITAR U.S. Citizenship required. Must be willing to work on government contracts and have the ability to obtain a security clearance. About AV: AV isn’t for everyone. We hire the curious, the relentless, the mission-obsessed. The best of the best. We don’t just build defense technology—we redefine what’s possible. As the premier autonomous systems company in the U.S., AV delivers breakthrough capabilities across air, land, sea, space, and cyber. From AI-powered drones and loitering munitions to integrated autonomy and space resilience, our technologies shape the future of warfare and protect those who serve. Founded by legendary innovator Dr. Paul MacCready, AV has spent over 50 years pushing the boundaries of what unmanned systems can do. Our heritage includes seven platforms in the Smithsonian—but we’re not building history, we’re building what’s next. If you're ready to build technology that matters—with speed, scale, and purpose—there’s no better place to do it than AV. Careers at AeroVironment